Biomass Design & Potential

Transcription

1 Biomass Design & Potential Mark Froling President Office & PDC Production Facility: 590 Hancock Road, Peterborough, NH

2 Biomass Design & Potential This course covers: The considerations one should make when designing and planning an automated biomass heating system

3 A Self-Performing Contractor What We Do: Biomass Boiler System Installations with Integration into Existing Boiler Systems Complete Project Management Biomass Boiler Servicing & Maintenance Manufacture & Delivery of PDCs

4 Our Experience: 145 Biomass Boilers Installed Fuel: Mostly wood pellet & dry wood chip at over 100 Customer Sites Plus Cleaning, Maintenance & Repairs

5 PART 1: Biomass Fuel Choices: Wood Pellets PDCs Green Wood Chips

6 3 BIOMASS FUELS TO CONSIDER DEPENDING ON FUEL CONSUMPTION AT YOUR BUILDING! PELLETS 3000 to 30,000 gallons of oil PDCs 20,000 to 70,000 gallons of oil (Precision Dry Wood Chips) GREEN CHIPS 40,000 gallons of oil to Huge

7 Wood Pellets 7% moisture content Precisely controlled small size Flows like water easy to store & move Compact BTU storage (by weight & volume)

8 PDCs Precision Dry Wood Chips 25% moisture content Screened: Nothing bigger than a matchbook Stacks does not flow. 90% hardwood

9 PDCs: A Value Added Product PDCs 25% Moisture Content Made from bole wood (the main trunk of a tree) Wood quality is similar to wood pellets (Bole wood) Screened to eliminate sticks, oversized chunks, rocks and Tramp metal Able to be blown into a bin through a 5 pipe as long as 150 feet Produced with quality control standards Does not require a large pit-type bin with roof, garage doors, live floor, etc

10 Green Wood Chips 35% to 50% moisture content (varies by season) Many Variables: Size, hard/soft wood, % bark Price is determined by Quality

11 GREEN CHIPS Wood Chips In General The more selectively produced = More expensive Whole Tree Chips Hardwood / Softwood Bole Wood Main tree trunk with bark

12 Comparing PDCs and Green Chips PDCs GREEN CHIPS Green Chips are more readily available Green Chips cost less Green chips require larger initial investments due to larger infrastructure requirements: Chip delivery & storage systems are bigger and more costly Fuel material handling systems are more robust/costly Green Chip systems usually employ single large boilers The Larger the Load: the more Green Chips make sense! Boilers over 2 million BTU/hr output are regulated in NH and must prove compliance with technical standards PDC boilers are usually less than 2 Million BTU/hr Green Chips can compost, generating heat or get moldy Must be managed bins emptied in summer

13 3 BIOMASS FUELS TO CONSIDER Volume per Ton PELLETS 50 cubic feet per Ton (Delivery: Blown into silo) PDCs 133 cubic feet per Ton (Delivery: Blown into bin) GREEN CHIPS 83 cubic feet per Ton (Delivery: Dumped into bin) Calculations use HHV energy content of hardwood burned at 84% Efficiency

14 3 BIOMASS FUELS TO CONSIDER Net (burned) Heat Content of Fuel PELLETS Gal Oil per Ton Million BTU per Ton PDCs 93.5 Gal Oil per Ton Million BTU per Ton GREEN CHIPS 66 Gal Oil per Ton Million BTU per Ton Calculations use HHV energy content of hardwood burned at 84% Efficiency

15 EXAMPLE: To Offset 30,000 Gallons of Oil PELLETS Need 249 Tons Total Biomass Boiler Output: 1.3 Million BTU Storage: 28 ton steel silo 9 fillings PDCs Need 321 Tons Total Biomass Boiler Output: 1.3 Million BTU Storage: 23 ton bin (Min) w/3100 cu ft 14 fillings using 15 ton truck GREEN CHIPS Need 486 Tons Total Biomass Boiler Output: 1.75 Million BTU Storage: 41 ton bin (Min) w/4000 cu ft 20 fillings using 25 ton truck Calculations use HHV energy content of hardwood burned at 84% Efficiency

16 3 BIOMASS FUELS TO CONSIDER Net Cost of Delivered Fuels $ per Million BTU PELLETS PDCs GREEN CHIPS Propane at $2.75/gal = $35.95 Oil at $3.00/gal = $27.02 Propane at $2.00/gal = Oil at $2.50/gal = $22.52 Propane at $1.50/gal = $19.61 Oil at $2.00/gal = $18.02 at $240/ton = $17.95 Oil at $1.50/gal = $13.59 Propane at $1.00/gal = $13.07 at $120/ton = $11.55 at $75/ton = $10.22 Oil at $1.00/gal = $9.06 at $60/ton = $8.18

17 HISTORICAL FUEL PRICES FOR OIL Propane or BIOMASS: PDCs $1.28 Green Chips $1.19-$.91 All prices noted in Net Oil Price Per Gallon Equivalents

18 3 BIOMASS FUELS TO CONSIDER Fuel Cost in Oil Equivalent with THERMAL RECs PELLETS Costs the same as $1.51/Gal Oil PDCs Costs the same as $.80/Gal Oil GREEN CHIPS Costs the same as $.42 to $.65/Gal

19 FUEL PRICES: BIOMASS With Thermal RECs!! Pellets $1.51 PDCs $.80 Green Chips $.42-$.65 All prices noted in Net Oil Price Per Gallon Equivalents

20 PART 2: Biomass Heating Systems

21 A Few Basic Biomass Boiler System Designs

22 Interior Pellet Storage Bag(s) with Pneumatic Feed to Boiler PELLETS

23 Pneumatic Pellet delivery trucks Quick & Easy 15 ton tanker 30 Ton Trailer

24 Interior Pellet Storage Bin with Augur and Pneumatic Feed to Boiler PELLETS

25 Exterior Pellet Storage Silo with Pneumatic Feed to Boiler PELLETS

26 Exterior Pellet Storage Silo with Auger Feed to Boiler PELLETS

27 PDCs Horizontal Auger Extraction System Interior Pellet Storage Bin with Auger Feed to Boiler

28 Our New Biomass Fuel: PDCs Made at our facility in Peterborough Delivered in our Box Truck and BLOWN into customer storage bins

29 DESIGN PARAMETERS for PDCs For 20,000 to 70,000 Gallons per year Consumption Storage Bin: Interior Sweeper Arm Type: 15, 23 or 34 tons each (Min/Max) 144/225/324 sq ft Each Bin supplies one or two Boilers Boilers are direct fed with rigid auger from Bin Bin must be close to Boiler (back to back) Boiler and Bin also able to handle pellets (Dual Fuel) New building often needed due to larger footprint

30 HIGH MOWING SCHOOL Wilton, NH PDCs PDCs are blown into the silos from our blower truck

31 HIGH MOWING SCHOOL Wilton, NH PDCs 2 Froling TX-150 Boilers = 1 Million BTU/hr Propane Back up = 1.5 million BTU/hr 9 Building District Heating System with Central Biomass Boiler Building Prior fuel use: 30,000 Gal Oil

32 GREEN CHIPS Shown: A Typical Messersmith System

33 GREEN CHIPS

34 GREEN CHIPS

35 Photo of Green Chip Delivery Truck (Live Floor) GREEN CHIPS

36 Example: Hanover High School Green Wood Chip Boiler System 5 Million BTU Max Output GREEN CHIPS

37 Example: Hanover High School Green Wood Chip Boiler System GREEN CHIPS A Cyclone is often required to remove particulates from the exhaust. In some cases an ESP is required in the exhaust stream (Electrostatic Precipitator)

38 DESIGN PARAMETERS for Green Chips For over 40,000 Gallons per year Consumption Interior Bin: 37 tons minimum (400 sq ft ) Design: Live Floor or Rake / Auger & conveyors Bin must be fairly close Boiler so conveyor system can get the chips up to the boiler Typically installed in new boiler room/house due to large footprint Usually employs one large boiler (100% Design Load) Boilers are fed by conveyors, pushers & augers

39 PART 3: Sizing for Financial Viability

40 When to switch to Biomass? PELLETS PDCs GREEN CHIPS Oil Boilers need to be replaced Oil Tank Inspection Results need repairs or replacement Green Initiative (Sets Green Example for Students and the Community) New Addition / New Building Performance Contract

41 Design Criteria PELLETS PDCs GREEN CHIPS How much fuel is consumed each year? (3-5 yr avg) What conservation steps reduce the heat load? Are other buildings close that could be in a District system? What physical constraints do the property present? Are other issues forcing a need to replace current equipment?

42 Issues & Challenges of Conversion PELLETS PDCs GREEN CHIPS Boiler room too small New Boiler House is necessary Difficulty locating fuel storage silo/bin near boiler Difficult access to silo/bin for Fuel Delivery Truck Steam Heat (Convert to FHW?) Availability of Natural Gas!

43 PELLETS PDCs Don t Oversize the System BUILDING DESIGN LOAD BIOMASS SYSTEM SIZE Size the Biomass System to be 65% to 75% of Design Load And cover 90% to 95% of annual heat needs. BACK-UP SYSTEM SIZE

44 PELLETS PDCs Don t Oversize the System! AVERAGE ANNUAL FUEL DEMAND Smaller Boiler Systems Cost Less. BIOMASS FUEL USED BACK-UP SYSTEM FUEL USED An average of only 7 days per year get close to Design Load.

45 GREEN CHIPS For BIG Fuel Users BUILDING DESIGN LOAD Size the Biomass System to be 100% of Design Load BIOMASS SYSTEM SIZE BACK-UP SYSTEM SIZE

46 GREEN CHIPS For BIG Fuel Users AVERAGE ANNUAL FUEL DEMAND BIOMASS FUEL USED BACK-UP SYSTEM FUEL USED And cover 80% of annual heating needs. WHY? When loads are too small these systems are turned off: Start Up in October & Turn Off in March

47 The 95% vs 80% Coverage Dilemna If you are burning 50,000 gallons of oil per year System Cost Estimate: Net Average Oil offset: $350,000 PDCs 95% or 47,500 Gal $500,000 GREEN CHIPS 80% or 40,000 Gal Average Biomass use: Biomass Cost: Average Thermal RECs: 507 tons per year at $120/Ton = $60,840 $15 = $23, tons per year at $60/Ton = $36,300 $15 = $23,130 Net Average Oil Use: Net Average Oil Cost: TOTAL Average Annual Fuel Cost: 2,500 $3.00 = $7,500 $45,210 10,000 $3.00 = $30,000 $43,170 At $40 a ton for Green Chips Fuel costs cut by $12,100

48 Economics of a Biomass Conversion PELLETS PDCs A simple economic analysis is tempting: Total System Cost Divided by Projected Average Annual Savings GREEN CHIPS HOWEVER: Other important factors may be pivotal. Buried Oil Tank is failing Existing Oil Boilers need replacement Energy Conservation Measures planned New Addition is being planned Switching from Steam to FHW

49 Making the Case for a Biomass System ROI and Payback models don t tell the Whole Story! A more realistic method is costing out Alternate Futures PLAN A: Stick with Oil Replace oil boiler in year X. Replace buried oil tank. Upgrade other components Yrs Fuel Costs PLAN B: Convert to wood pellet boiler system. Remove buried oil tank. Back up with Propane boilers Yrs Fuel Costs PLAN C: Convert to PDC boiler system + 10 Yrs Fuel Costs PLAN D: Convert to Green Chip boiler system + 10 Yrs Fuel Costs Include Rebates, RECs, Grants, etc in Each PLAN Include 10 to 20 years of projected future fuel costs in each PLAN Agree upon reasonable future fuel prices in projections ($3 Oil?) Keep fuel costs flat over the 10 to 20 year period

50 NH Pellet Boiler 30% Rebate PELLETS PDCs Rebate comes from NHPUC Wood Pellet systems ONLY Cap of $50,000 (+ $5,000 max for Buffer Tank) Apply in advance > Funds earmarked for you. Funds paid out when project is complete Best to apply before a public vote Must use recognized equipment and trained installers

51 NH Thermal RECs (Renewable Energy Credits) PELLETS PDCs GREEN CHIPS T-RECs available for any Biomass boiler system installed after January 1, 2013 Must have site approved by NHPUC Pellets get approximately 4 T-RECs per ton PDCs: 3/ton Green Chips 2/ton Generally:.0325 RECs per Offset gallon of Oil Requires Monitoring Equipment BTU Meter & Data Accumulator Requires Qualified Verification Sell T-RECs in NEPOOL System Directly or by Agent. Value varies approx $10-$25 each

52 PART 5: The Near Future and Cogeneration Options

53 Spanner CHP 45KW Electrical Power 108KW Thermal Power 81% overall efficiency Cost installed app. $300K

54 Froeling CHP 50 50KW Electrical Power 107KW Thermal Power 83% Overall Efficiency Installed Cost $350K

55

56 PART 6: Three Biomass Heating Projects

57 LYME ELEMENTARY SCHOOL Lyme, NH PELLETS

58 LYME ELEMENTARY SCHOOL Lyme, NH PELLETS Prior Oil Use: 10,000 Gallons/yr 2-340,000 BTU boilers do 95% coverage 28 ton Silo Propane back up can cover 100%

59 Projects CORNISH ELEMENTARY SCHOOL Cornish, NH PELLETS

60 Projects CORNISH ELEMENTARY SCHOOL Cornish, NH PELLETS

61 Containerized Boiler Rooms Built at our shop dropped into place by crane

62 Projects CORNISH ELEMENTARY SCHOOL Cornish, NH PELLETS Cornish School

63 CORNISH ELEMENTARY SCHOOL Cornish, NH PELLETS

64 Projects STEVENS HIGH SCHOOL Claremont, NH PELLETS PDCs

65 Projects Before STEVENS HIGH SCHOOL Claremont, NH PELLETS PDCs A large scale renovation was done in 2014 After

66 Projects STEVENS HIGH SCHOOL Claremont, NH Three 1970s Oil boilers were HUGE! PELLETS PDCs

67 Projects PELLETS PDCs STEVENS HIGH SCHOOL Claremont, NH 2 Froling TX-150 Pellet/PDC Boilers 500,000 BTU/Hr Each Steel Interior Silo can hold 70 tons of Pellets Or 35 tons of PDCs

68 Projects STEVENS HIGH SCHOOL Claremont, NH Constant Monitoring PELLETS PDCs

69 Questions?

70 Thank You!

71 A 30% Rebate is available now from the NHPUC for Commercial Bulk-Fed Wood Pellet Central Heating Systems (Schools & Municipal Buildings Included) For installation of bulk-fuel fed wood pellet boilers and furnaces of 2.5 million BTU Output or less Provides 30% of the cost of the boilers with installation, up to a maximum of $50,000. Must be operational before December 18, 2013.

72 RENEWABLE ENERGY CREDITS FROM THE NHPUC FOR CLASS I THERMAL SOURCES WITH RENEWABLE THERMAL ENERGY CAPACITY GREATER THAN 150,000 BTU/HR The Biomass boiler system installation must be completed with an approved energy production metering system in place A Registered Engineer must affirm that the installation meets the standards The official Application is completed, submitted and accepted by the NHPUC

73 RENEWABLE ENERGY CREDITS FROM THE NHPUC Current Values For each ton of biomass (wood pellets) burned you get about 4 Thermal RECs Thermal RECs can be sold each year at a set rate We expect them to trade for between $12 and $25 each year RECS were sold for $22 in the most recent sale

74 PART 7: More Biomass Heating Projects

75 NORTHWEST ELEMENTARY SCHOOL Rutland, VT PELLETS

76 PUTNEY SCHOOL Putney, VT PELLETS

77 CANAAN ELEMENTARY Canaan, NH PELLETS

78 RUTLAND HIGH SCHOOL & STAFFORD TECHNICAL CENTER Rutland, VT PELLETS

79 PART 4: Emissions Implications of Biomass Fuels

80 Proven Emissions Control Equipment Electro Static Precipitator (ESP) Metal Mesh Filter Bag House Ceramic filter Baghouse Cyclone

81 Massachusetts Emissions Limits so you can get Grants (200,000-3,000,000BTU) Sensitive Receptor Sites (Hospitals, Schools, Nursing Homes, Daycare Centers) PM 2.5 <.03 lbs/mmbtu/hr Nox <.22 lbs/mmbtu/hr CO <.18 lbs/mmbtu/hr General Sites PM 2.5 <.08 lbs/mmbtu/hr Nox <.22 lbs/mmbtu/hr CO <.18 lbs/mmbtu/hr

82 Equipment that will comply with regulations Complies in MA and NH with Pellets Fröling P4 Fröling T4 Fröling TX Fröling TM Needs ESP with Chips

83 Viessmann KRT and KPT Boilers Complies in MA and NH with Pellets 350MBH to 4300MBH Needs ESP with Chips